Tunnel liner and method of making same



Dec. 16, 1969 J. R. TABOR 3,483,704

TUNNEL LINER AND METHOD OF MAKING SAME Filed Dec. 16, 1966 2Sheets-Sheet 1 f INVENTOR' JOHN R. mam

Dec. 16, 1969 J. R. TABOR 3,483,704

TUNNEL LINER AND METHOD OF MAKING SAME Filed Dec. 16, 1966 2Sheets-Sheet 2 JOHN R. 734 80/? United States Patent O 3,483,704 TUNNELLINER AND METHGD OF MAKING SAME .lohn R. Tabor, 3460 Spruce St., Racine,Wis. 53403 Filed Dec. 16, 1966, Ser. No. 602,326 Int. Gl. E2141 11/08;E04!) 1/32; E94: 1/10 US. Cl. 61-45 16 Claims ABSTRACT OF THE DISCLOSUREA tunnel liner and method of making same having a plurality of blocks ina circle with wedge means between the blocks for radially expanding thecircle upon axial displacement of the wedge means. Alignment andsecuring dowels, and also waterproofing pieces are disposed betwen theblocks for assembly, strength, and waterproofing of the liner.

BACKGROUND OF THE INVENTION This invention relates to a tunnel liner andmethod of making same. The liner disclosed utilizes concrete blockswhich are disposed in a circle and are particularly useful in lining thewall of a tunnel in the ground.

The prior art has employed concrete blocks for lining ground tunnels,and these blocks are commonly arranged to have tapered or wedge-shapedfaces so that when the blocks are disposed in their circular form, axialforce on the blocks will cause the circle to expand to the diameter ofthe tunnel cut in the ground. Thus, a tunneling machine is commonlyprovided with a forwardly located cutter and a rearwardly located skirt.It is common practice to initially dispose the blocks in a circle of acircumference less than that of the full circumference of the cut in theground. Then the blocks are expanded in their circular pattern so thatthey have a circumference comparable to that of the ground, and theblocks thus provide a liner which is in abutment with the ground andthereby gives desired support. Further, the radial expansion of theblocks is known to have been accomplished by applying a force on theblocks in a direction axially of the circle of blocks. US. Patent No.1,336,789 shows these features. However, that type of prior art requiresa block of a complex shape which is difiicult to manufacture and tohandle without damage to the blocks. Where that block of the prior artis made exclusively of concrete, it is subject to breakage when theblocks are placed in abutment and are forced together. While concreteblocks are capable of resisting large compressive forces, they arenevertheless susceptible to chipping and cracking when subjected toconcentrated forces on only a line or a limited area of the block, andthis is likely to be the case with the prior art blocks mentioned.Further, the axial forces are applied directly to the prior art blocks,and, in the instance of the one prior patent cited above, the force isapplied to only half of the blocks in any one course of blocks, as thereis no continuous planar wall of blocks for receiving the surfaceapplying the axial force.

Further, in the prior art where only the concrete blocks are in directabutment with each other, the tunnel is subject to water leaks, unlessit is elaborately treated .with extensive grouting between the joints.In the present invention, the tunnel is arranged in a waterproof mannerat the same time that it is assembled, and such waterproofing is even ofa self-sealing nature where intervening pieces of wood or like materialare employed between the blocks so that the wood can absorb the forceswhich might otherwise damage the block and it can water-proof byexpanding when it is moist and is thereby self-sealing. Still further,the intervening pieces are utilized for assembly in assisting thealignment of ice the blocks, and they are also utilized for reinforcingin the strength of the liner in final assembly as they are available forresisting forces tending to shear the liner as well as absorbing theforces axially of the liner. Further, where resilient pieces areutilized between the concrete material of the blocks, such as wherewooden dowels and seal pieces are used, the entire liner is moreshockproof and is also more capable of adjusting to different requiredpositioning due to any ground shifting or the like. So the interveningresilient pieces are available for both the absorbing of shock when theliner is finally assembled, and also for cushioning between the concretematerial of the blocks when the liner is being assembled so the blockswill not be damaged by any concentrated stress applied to the concretematerial, such stress being notorious for cracking concrete blocks.

Still further, it is common practice to stagger blocks which form awall, and, in this instance, alignment means, such as dowels, areprovided for the staggering which must follow the requirements of thedowels according to positions and sizes of the dowels. In accomplishingthis, the dowels are shown to be disposed in certain positions and areof at least two different sizes so that they must mate with the adjacentblock in a manner which assures the desired staggering of the blocks.This feature, and the aforementioned features of this invention, allprovide a means and method for a tunnel wall which is easy to erect, canbe erected at a pace which is comparable to the speed at which thetunneling machine can operate, it reduces the need for reinforcing meanssuch as steel beams, and it reduces the cost of constructing a tunnelhaving the strength characteristics of the concrete block type oftunnel. Also, it provides both a means and a method for constructing aconcrete block tunnel wherein the force required for expansion of thecircumference of the tunnel need not be applied directly to the concreteblock. Instead, the force can be applied to pieces of wood or likematerial inserted between the blocks, and these pieces are more capableof receiving large forces without damaging the wood pieces or theconcrete block.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a top plan view of oneembodiment of a block of this invention, and FIG. 2 is a frontelevational view.

FIG. 3 is a plan view of a fragment of a wall in assembled position.

FIG. 4 is an end axial view of the ground tunnel and the tunnel wallprior to the expansion of the wall.

FIG. 5 is an elevational view of the left hand face of the block in FIG.2.

FIG. 6 is a side view of a pin disposed between the blocks.

FIG. 7 is an end elevational view of a dowel disposed between theblocks, and FIG. 8 is a side elevational view of FIG. 7.

FIG. 9 is a top plan view of another embodiment, and FIG. 10 is a frontelevational View.

FIG. 11 is a wall fragment plan view of this other embodiment.

DESCRIPTION OF THE METHOD AND PREFERRED EMBODIMENTS A block 10 is shownto be elongated and arcuate, in its display in FIG. 2, and the block ispreferably made of concrete. It has oppositely disposed planar faces 11and 12, and end walls 13 and 14. Dowels 16 and 17 are cast into theblock to project from the wall 11, as shown in FIG. 1. Also, awater-proofing piece 18, which may be a strip of wood, is disposed inthe block to project from the face 12 as shown in FIG. 1. The strip 18is disposed in a groove 19 in the block 10, and there may be three 3such strips 18 in each face 11 and 12, as three grooves 19, 21 and 22are provided in each face 11 and 12, as shown.

The end walls 13 and 14 have tapered openings 23 and 24 formed therein,and with the openings being shown to be half-circles. Finally, the blockhas tapered openings 26 and 27 formed in the face 12. Thus the entireblock 10 can be cast in concrete material, and the holes, openings,grooves, and the like can all be cast directly into the material, andthe dowels 16 and 17 can also be cast into the concrete.

FIG. 3 shows the assembly of the blocks in a tunnel liner, and it willbe noted that the blocks are staggered so that there is no extendedjoint line, and the liner is therefore of optimum strength and minimumwater susceptibility. Further, it will be noted that every two adjacentblocks 10 have a tapered pin 28 disposed therebetween, and the pin 28may be made of wood. Likewise, the dowels 16 and 17 may be made of acore 29, of wood, and a casing 31 of metal. These dowels 16 and 17 mayalso be tapered to be smaller at the projecting ends, as shown inFIG. 1. The liner as shown in FIG. 3 is indicated to be in the expandedcondition, and that is accomplished by placing a force axially of thecircularly disposed blocks, as shown in FIG. 4. Thus the force forexpansion is applied to the tapered pins 28 which are disposed in theblock tapered holes 23 and 24, and axial displacement of the pins 28relative to their blocks 10 will cause the blocks to spread apart withrespect to each other, as indicated in the spacing designated 32 in FIG.3. This spacing might therefore exist between every two adjacent blocks10 so that the circumference of the assembly of a plurality of blocks10, as shown in FIG. 4, would be enlarged from that shown in FIG. 4.until it is the size of the circumference designated 33 of the tunnel inthe ground indicated at 34 in FIG. 4. This is of course the desiredfinal disposition of the blocks 10, so that they are in abutment withthe tunnel wall or circumference 33 to give maximum support to thetunnel wall 33.

Of course the blocks 10 are assembled in the tunnel wall one by one, andapparatus (not shown) may be used for positioning the blocks in theirrespective positions and courses to construct the cylindrical tunnel ofblocks.

To cause the radial and circumferential expansion described, the pins 28have their ends 36 of a diameter comparable to the diameter of theconical hole formed by the half-circles 23 and 24 at the large end, thatis at the wall 12. Then when the pins 28 are axially displaced, theywill of course cause the wall expansion desired. Suitable jacks (notshown) can be applied to the pins 28 at their large ends 37 to force thepins between the adjacent blocks 10, and slightly therebeyond, as shown.Thus the length of the pins 28 is comparable to the width of the blocks10 from faces 11 to faces 12. This means the pin ends 36 protrude, asshown in the first course of blocks shown in FIG. 3, and the pin ends 37are countersunk, as most clearly shown in the last or lower course ofblocks shown in FIG. 3.

Dowel 17 is thus shown constructed as mentioned, that is, with the dowelbeing made of a wood core 38 and a metal casing 39. The dowel 17 is alsotapered, and in both dowel 16 and 17 the cores are of wood and are shownto extend slightly beyond the metal casings. Thus when the blocks 10 areassembled as shown in FIG. 3, and the axial forces applied to the pins28, the dowels 16 and 17 are respectively received in the holes 27 and41 where 41 is a hole formed by the block holes 23 and 24 and cleared bythe countersinking of the pins 28, as mentioned. Since the dowels 16 and17 are of different diam eters, the assembly of the tunnel from courseto course is guaranteed to be in proper relationship. Further, the pinprojecting ends 36 are received in the tapered openings 26 in theadjacent course of blocks. In all instances of these various dowels andpins extending into their respective op n g o ho s, t e fit s such. thah d9 a P l will easily commence insertion, and, upon forcing axially ofthe tunnel, the projecting dowels and pin ends will become some whatcompressed in that the fit is tight in final assembly. Thus theresilient or wood material is utilized so that it can be compressed forsecuring the courses together and creating a structure having maximumresistance to damaging forces. Also, the wood strips 18 disposed betweenthe block faces 11 and 12 on adjacent blocks 10 are available for slightcompression in the assembly of the wall courses, and these stripsprovide water-proofing between the courses. Thus the projection of thewood strip 18, as shown in FIG. 1, would insert into the mating groove19 on the adjacent 'block 10, and specifically on the wall 11 of thatadjacent block. When these wood pieces 18, and also the wood pins anddowels described, are subjected to moisture, they tend to expand andthereby enhance their water-proofing characteristics, and they evenenhance the strength of the tunnel liner.

Thus FIG. 3 shows that a first course of blocks, generally designated42, may be set up in a ring or circular arrangement, and subsequentcourses 43 through 46 would also be located. Each course could have itspins 28 subjected to an axial force designated A in FIG. 3 and appliedby power means such as a jack which is not shown. The force A would beapplied to the pins prior to the assembly of the next adjacent course ofblocks. This will also cause the dowels 16 and 17 to become firmlyseated in their respective mating holes, and the metal casings on thedowels 16 and 17 are available for resisting forces tending to shear thecourses apart. The dowels 16 and 17 are therefore disposed across thejoint be tween courses, and this is a plane designated 47 in FIG. 3, andit will be noted that the plane 47 forms an endless and continuous wallby the block faces 12 so that any assembly forc transmitted to therespective courses is equally transmitted to the entire course. Thedowels 16 and .17 are shown to have the split casings 31 and 39 so thatthese casings can contract to the extent neces* sary to be snug withintheir respective holes on the adjacent blocks, as their respective woodcores 29 and 38 are slightly crushed to thereby absorb the assemblyforces and be desirably snug and provide a firm grip between the coursesin the final assembly.

So that no special block construction is required for gripping andraising the blocks into the position shown in FIG. 4, block placerapparatus of a suction type which would grip the blocks, could be used.This would therefore eliminate the need for any special additional gripmeans on the block or any hooks applied to the blocks or any enlargedopenings in the blocks for gripping same, and the blocks thereforeremain at maximum density and strength. Still further, the jack force Amay be applied by the cutting machine itself, in any Well-known manner.So the direction of machine cutting in tunneling is shown by arrow B inFIG. 3, and jack forces A are machine reaction forces. The method stepshav been described in the foregoing, and they may be carried out byhand. The blocks could be placed by hand, and the pins 28 dis placed byhand to expand the ring of blocks, shown in IgG. 4, into thecrescent-shaped void space designated Of course the block could be madeof material other than concrete, and it could be made of somewhatdifferent shape and with different dowels and holes. FIGS. 9, 10 and 11show another embodiment of the block which can be used in the mannerdescribed in connec tion with block 10. A block 51 is shown to beprovided with one large dowel 52 being of a tapered form and having acenter core 53 which is of a resilient material, such as wood. The dowel52 also has a metal or hard casing 54 which is split, as shown, so thatagain it will compress and even crush the core 53 in the assembly, as described. A small tapered hole 56 is provided in the block 51, and itwill be noted that the dowel 52 is on one block ew 5 d e s 56 son t eoppa i e blac e The end walls 59 and 61 of the block 51 have taperedopenings 62, and these openings are available for receiving wedge means,such as the pin 28.

The block 51 also has grooves 63 which extend along the faces 57 and Sand between the openings in the blocks, and these grooves receiveself-sealing water-proofing material, such as wood strips 64 and 66. Itwill therefore be apparent that when the blocks are assembled incourses, such as the three courses 67, 68 and 69 of FIG. 11, the stripsprovided on the block face 58 will be inserted into the openings 63 onthe adjacent course of blocks and along the faces 57 of this adjacentcourse.

Also, as shown in FIG. 11, the pins 28 are substantially the size andshape necessary to radially expand the ring or circle of blocks 51. Thusthe pins 28 are of a length approximately equal, at least, to thethickness of the block 51. Then the pins can again be countersunk inassembly, as shown in FIG. 11, and their ends 36 will project beyond theplanar wall or plane between the courses of blocks. The projecting pinend 36 will then be received in the hole 56. In this manner, the blocksare aligned, secured, and of course staggered as shown in FIG. 11, asdesired. Also, the tapered dowel 52 is then received in the holedesignated 71, and this is the hole or opening provided by thecountersinking of the pin 28. Again, the diameter of the pin 28 islarger than the corresponding cross-section of the adjacent holes 62 forthe wedging described.

While specific embodiments and method of making same have been shown anddescribed, it should be obvious that certain changes could be madetherein and the invention should therefore be determined only by thescope of the appended claims.

What is claimed is:

1. In a tunnel liner including blocks adaptable to hav a plurality ofsaid blocks disposed in an end-to-end circular relation and inface-to-face circular courses to form a circular lining for a tunnel inthe ground, and having wedge means disposed to be operative between saidblocks for radially displacing said blocks by a force axial of thecircle for expanding the circle, the improvement which comprises theopposite ends of said blocks having recesses tapered at the angle whichis on said wedge means and with said blocks being adapted to be arrangedin courses with each having an endless planar end wall and with saidwedge means being located in said recesses at said opposite ends of saidblocks and at the joints therebetween and with said wedge means beingpieces separate from said blocks to expand said circle upon displacementof said wedge means relative to said blocks and axially of said circleand upon forcing said planar end wall toward the adjacent one of saidcourses, and with said angle on said recesses and said wedge mens beingtapered in the axial direction of said tunnel.

2. The subject matter of claim 1, wherein said wedge means is a taperedwooden pin for radially displacing said blocks upon axial displacementof said pins with respect to said blocks.

3. The subject matter of claim 2, including one face of said blockshaving holes therein and dowels extending from the face of said blockson the side opposite said one face, and wherein pins are countersunkwith respect to said blocks at one end of said pins, and said pinsextend beyond said blocks at the other end of said pins, and said dowelsbeing mated in the openings provided by the countersinking, and theextensions of said pins being mated in said holes, all for aligning andsecuring said blocks and said courses together.

4. The subject matter of claim 1, including pieces disposed between saidblocks at the faces thereof between said courses, and said pieces andsaid wedge means being of a material which is resilient and isself-sealing waterproofing respectively with said faces and said ends ofsaid blocks.

5. The subject matter of claim 1, including mated members and holes onrespective adjacent ones of said blocks in adjacent course matedtogether for aligning and securing said courses of said blocks together.

6. The subject matter of claim 5, wherein said members are taperedwooden dowels and said holes are of a crosssectional size to be snugwith said dowels upon forcing said courses of said blocks toward eachother.

7. The subject matter of claim 5, wherein said members are a combinedwooden core and an outer casing and arranged to form a tapered dowel,and said holes are of a cross-sectional size to separately snuglyreceive said dowels to cause side dowels to be radially compressed andto thereby grip said blocks together when said blocks are displaced toaxially force said dowels into said holes.

8. The subject matter of claim 7, wherein said dowels and said holes areboth mutually tapered for ease of entrance of said dowels into saidholes and for radial compression of said dowels upon axial movement ofsaid dowels into said holes.

9. The subject matter of the combination of claims 1, 2, and 5.

10. The subject matter of claim 5, wherein said block is arranged to beasymmetrical by having said members on each of said blocks of differentsizes for necessitating staggering of said blocks between said courses.

11. In a tunnel liner including blocks adaptable to have a plurality ofsaid blocks disposed in an end-to-end circular relation and inface-to-face circular courses to form a circular liner for a tunnel inthe ground, and having wedge means disposed to be operative between saidblocks for radially displacing said blocks by a force axial of thecircle for expanding the circle, the improvement which comprises saidwedge means being disposed between the ends of said blocks at the jointsof said liner and being of a material which is resilient and isself-sealing water-proofing with said ends of said blocks, said wedgemeans extending beyond the thickness of said course of blocks, and saidblocks having openings therein for reception of the extending ends ofsaid Wedge means.

12. In a method of lining a tunnel with blocks disposed in a circle toform the tunnel wall and expanding the circle by a force applied to saidwall axially of said circle, the improvement which comprises the stepsof disposing said blocks in a circle and having tapered recesses in bothopposite ends of each of said blocks and with the taper being orientedin the direction of the axis of said circle, placing wedge-shaped piecesin said tapered recesses between the ends of every two of adjacent onesof said blocks, and forcing all said wedge-shaped pieces along saidtapered recesses and axially of said circle and thereby increasing thediameter of said circle by forcing all said blocks away from each otherand radially outwardly under the influence of the axial force.

13. The method claimed in claim 12, including the steps of arrangingsaid blocks with projecting dowel pins and mating holes and arrangingsaid dowel pins and said holes in said blocks on their respective faceswhich are parallel to the right-angle radial plane of said circle, andforcing said dowel pins and said holes into snug mating relation by theaxial force applied.

14. The method claimed in claim 12, including the step of compressing acompressible and self-sealing waterproofing iece between the faces ofsaid blocks by the axial force applied.

15. The method claimed in claim 13, including the step of compressing acompressible and self-sealing waterproofing piece between the faces ofsaid blocks by the axial force applied.

16. The method claimed in claim 12, including the step of forming saidtapered recesses and said wedge-shaped pieces in a conical shape forforcing said wedge-shaped pieces in both the radial and tangentialdirections on said blocks by the axial force applied.

(References on following page) References Cited UNITED STATES PATENTSButler 61-45 McGowan 287-127 ORourke 61-45 Coyle 61-43 ORourke 61-45Ruskin 287-127 Phipps 52-396 8 FOREIGN PATENTS 724,853 2/1955 GreatBritain.

JACOB SHAPIRO, Primary Examiner US. Cl. X.R.

